D4D engine Problems

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

Hi All,
I am new here and am looking for advice as I am at a loss and need some help. I have a Toyota Hiace 2008 with 1KD- FTV engine that is causing me problems. I am a courier and the engine started developing problems a while back when it failed to idle and sometimes lost power and engine light came on, the fix was to replace the EGR valve which was totally clogged. Since the replacement it was working fine but some time later it began to lose power again. I use a mechanic that I work next door to and they had another look for me and discovered that the EGR cooler was blocked. On cleaning the EGR cooler it ran well for some months then began to lose power again. The EGR cooler was then taken off again and cleaned and resolved the problem, since then every three weeks or so it loses power again, take off the cooler and clean it and it resolves the problem. I finally bit the bullet as I assumed the EGR Cooler was blocked inside an unable to be cleaned properly so I bought a new one at $ 950. This again fixed the problem but three weeks down the track it has lost power again. The light on the dash although initially off when the EGR valve was replaced is now constantly flashing. I believe the error code is saying something about CO2 gasses. The van has done approx. 180 000 Km s and the injectors were replaced 25000 Km ago under the Toyota recall. My mechanics seem to be at a loss and I have no idea and I cant afford to have it off the road as it is impossible to hire a van where I live and am scared about taking it to Toyota . My mechanics next step is to pull of the intake system to see if its carboned up . Any thoughts or solutions to this problem greatly appreciated. Thanks in advance Regards Greg .

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Recall - what recall was that?

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Wasn't there a recall on the vans to replace injector pipes? Not the injector assembly just the pipes. #### will know. ####? Wakey wakey...

Greg I suspect you have had lots of blowby which has filled the inlet tract with oily residue. Just cleaning the EGR won't get rid of the problem. It will keep filthing up the system, you need a full intercooler and inlet clean out. Check that your injectors really were changed out because you may have bigger issues around the corner. If all ok on the injector front then clean the inlet and fit a catch can. Yours is a top mounted intercooler?

[AussieAndy Find all posts View Profile Close AussieAndy]

It's a recall for hiace vans only, replace the injectors!! Something to do with the injectors failing because of the heat in the van application. Have had lots of fleet vehicles we work on back to the dealer to get this done.

All hiace with the 1KD have a front mounted intercooler, and are different to any other motor (not the same as any prado or hilux in Australia)

What is the actual fault code?

I have come across this problem before, but after a thorough EGR and intake clean it has been resolved. As per Toyota's own bulletin, BBQ cleaner is used to clean out the cooler, fill it with cleaner and let it soak, usually overnight because of how bad they are. It seems like you have tried all these though so I'm kinda at a loss. I have found that courier type work seems to block them up quicker, lots of stop start.

I guess as a last resort I would pull the entire intake manifold off, and ensure it is spotless. From the intercooler pipe to the head, including the egr cooler. Pay particular attention to the EGR valve and make sure it is clean. Sounds like your mechanic is on the right track if it is the code I think it is (it's usually this on, sorry, can't remember it off the top of my head, would have to look it up at work)

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

Great start thanks . Hopefully on track. Yes the vans had a recall and all injectors and pipes were replaced at a cost of $ 6000 to Toyota. Will try and find out the code Cheers

[BlakMoth Avid PP Poster! Find all posts View Profile Close BlakMoth]

How old is the van Greg? I've got a 2010 that's getting a bit rattly. Will be getting a clean out in the new year


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[Pragueprado Junior Member Find all posts View Profile Close Pragueprado]

Could be something as simple as the MAF sensor needing to be cleaned - although if it is that, I'm not sure why you'd be going three weeks between it running well and dying. Still, wouldn't hurt to start with the simple stuff.

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

How old is the van Greg? I've got a 2010 that's getting a bit rattly. Will be getting a clean out in the new year


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Hi it's a 2008 model and yes I have heard that because of the nature of stop start and no proper runs this can cause problems. Think I might have to get them to pull off the intake. Thanks guys much appreciated

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

Just an update on this. I had the intake removed and cleaned by my mechanic and yes it was clogged 5/1/15 . This cured the problem and power has been restored but the light is still on . This week it started again to lose power and torque. The only thing that wasn't replaced was the EGR butterfly, (excuse my term I think that is what it is called ) we were able to source a second hand one to test thanks to Gympie 4wd wreckers which we swapped over yesterday. Initially it made no difference and light was still on. I brought it back and he was able to clear the light on the scanner and power has been restored . The light initially stayed off but now light is back on again but power is normal. This is starting to do his head in and mine, the second hand butterfly seems to be doing the job but it is no guarantee that there is anything wrong with my original part. The fault code we are getting is P2BAB Nox Exceedence - Incorrect EGR flow. Please help we are at the end of the line Cheers

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Just an update on this. I had the intake removed and cleaned by my mechanic and yes it was clogged 5/1/15 . This cured the problem and power has been restored but the light is still on . This week it started again to lose power and torque. The only thing that wasn't replaced was the EGR butterfly, (excuse my term I think that is what it is called ) we were able to source a second hand one to test thanks to Gympie 4wd wreckers which we swapped over yesterday. Initially it made no difference and light was still on. I brought it back and he was able to clear the light on the scanner and power has been restored . The light initially stayed off but now light is back on again but power is normal. This is starting to do his head in and mine, the second hand butterfly seems to be doing the job but it is no guarantee that there is anything wrong with my original part. The fault code we are getting is P2BAB Nox Exceedence - Incorrect EGR flow. Please help we are at the end of the line Cheers

Hard one from here.
Sounds like a p.i.t.a.
So the egr cooler is blocking up? Is it dry soot? Or?

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

Excuse ignorance what is p.i.t.a. Yes cooler was blocking but a brand new one has been bought. Funny though before I bought new one it would lose power I would take off cooler clean and then it would go ok for three weeks and lose power again. Stuffed if I know. Miight have to burn it.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

P.i.t.a - pain in the armpit. Or body part of your choice starting with a.

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

So is it dry soot blocking it?

Is the egr stuck open? Have you done egr diagnostic & looked at egr operation?

[gregsimpson Lurker Find all posts View Profile Close gregsimpson]

Yes originally but all this has been cleaned including manifolds. New EGR valve , new EGR cooler . Friday fitted second hand EGR butterfly that seems to have done the job but light still on.